Waveguide sensor assemblies and related methods

ABSTRACT

Methods for manufacturing a vehicle sensor module, such as a RADAR sensor module. In some implementations, the method may comprise forming a sub-assembly comprising a plurality of stacked layers formed into a self-contained radome and adhering the sub-assembly to a first side of an antenna block, the first side comprising a plurality of waveguide grooves formed therein. The sub-assembly may be applied so as to provide a weatherproof seal to each of the plurality of waveguide grooves formed in the antenna block. A PCB layer may be applied to a second side of the antenna block opposite the first side and the antenna block may be seated within a cover such that the second side is protected by the cover and the first side is protected by the self-contained radome.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of co-pending Application Ser. No.16/224,647 titled “WAVEGUIDE SENSOR ASSEMBLIES AND RELATED METHODS”filed on Dec. 18, 2018, which application is hereby incorporated hereinby reference in its entirety.

SUMMARY

Disclosed herein are various embodiments of sensor assemblies andrelated elements, sub-assemblies, and manufacturing methods. Inpreferred embodiments and implementations, such assemblies may compriseRADAR sensor modules for vehicles, including one or more novel andinventive features.

For example, in some embodiments disclosed herein, an antenna block,which may comprise a casting, may have features designed to establishthe foundation for one or more waveguides and may provide the primarysupport structure for various means for coupling the sensor assembly toa vehicle. For example, an array of one or more waveguide grooves may beformed, in some cases with waveguide ridges formed therein. A film orother layer, such as a conductive adhesive layer, may be used to couplea conductive sheet comprising antenna slots to the block. A top layerthat may comprise an adhesive plastic film in some embodiments, may forma radome or weather seal to the assembly.

In some embodiments, a cover may be coupled to the block/casting, suchas by crimping a frame to a recess formed in the block/casting and/orover-molding the cover with a potting material, sealant, and/or othersuitable material to provide a suitable seal.

In a more particular example of a vehicle RADAR module according to someembodiments, the assembly may comprise an antenna block defining a firstarray of waveguide grooves on a first side of the antenna block. Theassembly may further comprise a slotted layer comprising a plurality ofslots that may be at least partially aligned with the waveguide groovesof the antenna block. In some embodiments, the slots may be fullyaligned with the waveguide grooves. An adhesive layer may be positionedin between the antenna block and the slotted layer. A cover may becoupled to the antenna block such that at least a portion of the antennablock is recessed within the cover. In some embodiments, a lower portionof the antenna block may be recessed within the cover and an upperportion may protrude above the cover. One or more mounting tabsconfigured for mounting the vehicle RADAR module to a vehicle may beprovided. In some embodiments, the one or more mounting tabs may be anintegral part of the antenna block, which may comprise a casting.

In some embodiments, the array of waveguide grooves may be formed byproviding a plurality of adjacent posts that collectively define one ormore such grooves. Alternatively, the grooves may be formed by simplyforming one or more trenches within a surface of the antenna block. Someembodiments may further comprise a second array of waveguide groovespositioned on a second side of the antenna block opposite the firstside.

In some embodiments, the at least one mounting tab may protrude beyond aperimeter of the cover. For example, the cover may be molded orotherwise formed below the at least one mounting tab. Alternatively, thecover may comprise an opening through which the at least one mountingtab may extend so as to protrude beyond the perimeter of the cover.

In some embodiments, the at least one mounting tab may comprise amounting feature configured to engage a corresponding mounting featureon a vehicle, such as a fastener opening, a snap-fit prong, a snap-fitgroove, a mounting bracket, and/or a mounting post.

In some embodiments, the antenna block may comprise a recess, such as anannular recess. In some such embodiments and in related implementationsof manufacturing methods, the cover may comprise a rim engaged withinthe recess to affix the cover to the antenna block. In some suchembodiments and implementations, the cover may be crimped to the antennablock at the recess so as to form the rim therein.

Some embodiments may further comprise a plurality of ridges extendingwithin the waveguide grooves. In some such embodiments, each of thewaveguide grooves comprises a corresponding ridge formed therein.

In an example of a vehicle sensor antenna assembly according to otherembodiments, the assembly may comprise an antenna block defining anarray of waveguide grooves on a first side of the antenna block. Aslotted layer, such as a conductive metal or other sheet, comprising aplurality of slots may be adhered or otherwise coupled to the antennablock, in some embodiments with the slots at least partially alignedwith the waveguide grooves of the antenna block (in some embodiments,the slots are fully aligned with the waveguide grooves such that theentire grooves are left unexposed by the slots). An adhesive layer maybe positioned in between the antenna block and the slotted layer, whichmay be used to adhere the slotted layer to the antenna block. Theadhesive layer may comprise, for example, an adhesive tape (preferablyconductive) or a solder layer.

In some embodiments, the antenna block may further comprise a secondarray of waveguide grooves, which in some embodiments may be separatefrom the grooves on the first side and/or spaced apart from the firstside. In some such embodiments, the second array of waveguide grooves ispositioned on a second side of the antenna block opposite from the firstside. One or more (in some embodiments, each) of the waveguide grooveson the array may at least partially overlap with a correspondingwaveguide groove of the second array. In some such embodiments, the twoarrays of waveguide grooves may be fully aligned such that each grooveon one surface/side has a corresponding groove on the oppositesurface/side that is at the same position along two dimensions relativeto the opposite groove.

Some embodiments may further comprise a printed circuit board. In somesuch embodiments, a second adhesive layer may be positioned between theprinted circuit board and the second array of waveguide grooves on theantenna block.

In an example of a method for manufacturing a vehicle sensor moduleaccording to some implementations, the method may comprise adhering afirst conductive adhesive layer to a first side of an antenna block,such as a casting. The antenna block may comprise a plurality ofwaveguide grooves, which may be defined by, for example, a series ofposts or by one or more trenches formed in the antenna block. A slottedlayer comprising a plurality of slots may be coupled to the antennablock adjacent to the plurality of waveguide grooves. In someimplementations, the slotted layer may be coupled to the antenna blockusing an adhesive layer, such as preferably a conductive adhesive layer,which conductive adhesive layer may also comprise slots at leastpartially aligned with the slots of the slotted layer. In someimplementations, the slotted layer may be coupled to the antenna blocksuch that one or more (in some such implementations, all) of thewaveguide grooves is at least partially, or in some such embodiments,fully, aligned with the slots formed in the slotted layer.

A cover may be coupled to the antenna block such that a second side ofthe antenna block opposite the first side is recessed within the cover.In some implementations, the cover may be coupled to the antenna blockby crimping at least a portion of the cover, such as a frame of thecover, to the antenna block. For example, in some implementations, theantenna block may comprise a recess, and the cover may be crimped to theantenna block within the recess, such as by forming a rim or othersuitable bent/crimped portion that extends within the recess to securethe cover to the antenna block and/or the rest of the module/assembly.

In some implementations, a sealant, such as a potting compound, may beapplied about the cover to define a sealed cover.

In some implementations, the antenna block may further comprise one ormore mounting tabs configured for mounting the vehicle RADAR module to avehicle. In some such implementations, the mounting tab(s) may extendintegrally from the antenna block, such as an integral part of a castingforming the antenna block. In some implementations, the cover may becrimped to the antenna block within the recess such that the mountingtab(s) protrude beyond a perimeter of the cover. The mounting tab(s) maycomprise one or more locating and/or orientation features to furtherfacilitate proper installation and/or assembly if desired.

Some implementations may further comprise applying a weather seal to thefirst side of the antenna block. This may be formed by applying anadhesive layer to the upper surface of the assembly. In some embodimentsand implementations, a layered, weather seal sub-assembly may be appliedto the first/upper side of the antenna block. This sub-assembly maycomprise, for example, a layered “sticker” that may include the firstconductive adhesive layer, the slotted layer, and a weather seal layersandwiched together in a self-contained assembly.

Some implementations may further comprise coupling of additional layers,such as additional slotted layers, adhesive layers (such as to theopposite side of the casting, as discussed in greater detail below, orcoupling of a PCB layer to the assembly.

The features, structures, steps, or characteristics disclosed herein inconnection with one embodiment may be combined in any suitable manner inone or more alternative embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

Non-limiting and non-exhaustive embodiments of the disclosure aredescribed, including various embodiments of the disclosure withreference to the figures, in which:

FIG. 1 is a perspective view of an antenna block that may beincorporated into an antenna assembly, such as a vehicle RADAR sensorassembly, according to some embodiments;

FIG. 2 is an exploded view of the antenna block of FIG. 1 along with aslotted layer that may be coupled with the antenna block to form anantenna assembly;

FIG. 3 is an exploded view of an antenna assembly comprising an antennablock, a slotted layer, and an adhesive layer according to otherembodiments;

FIG. 4A depicts the slotted layer of the embodiment of FIG. 3;

FIG. 4B depicts the adhesive layer of the embodiment of FIG. 3;

FIG. 4C depicts the antenna block of the embodiment of FIG. 3;

FIG. 5 is an exploded, cross-sectional view of a sensor assemblyincluding each of the layers of FIGS. 4A-4C;

FIG. 6 is a cross-sectional view of a sensor assembly according to stillother embodiments; and

FIG. 7 is an exploded, cross-sectional view of a sensor assemblyaccording to further embodiments.

DETAILED DESCRIPTION

A detailed description of apparatus, systems, and methods consistentwith various embodiments of the present disclosure is provided below.While several embodiments are described, it should be understood thatthe disclosure is not limited to any of the specific embodimentsdisclosed, but instead encompasses numerous alternatives, modifications,and equivalents. In addition, while numerous specific details are setforth in the following description in order to provide a thoroughunderstanding of the embodiments disclosed herein, some embodiments canbe practiced without some or all of these details. Moreover, for thepurpose of clarity, certain technical material that is known in therelated art has not been described in detail in order to avoidunnecessarily obscuring the disclosure.

The embodiments of the disclosure may be best understood by reference tothe drawings, wherein like parts may be designated by like numerals. Itwill be readily understood that the components of the disclosedembodiments, as generally described and illustrated in the figuresherein, could be arranged and designed in a wide variety of differentconfigurations. Thus, the following detailed description of theembodiments of the apparatus and methods of the disclosure is notintended to limit the scope of the disclosure, as claimed, but is merelyrepresentative of possible embodiments of the disclosure. In addition,the steps of a method do not necessarily need to be executed in anyspecific order, or even sequentially, nor need the steps be executedonly once, unless otherwise specified. Additional details regardingcertain preferred embodiments and implementations will now be describedin greater detail with reference to the accompanying drawings.

FIG. 1 depicts an antenna block 110 that may be incorporated into avehicle sensor, such as a RADAR sensor assembly, according to someembodiments. Antenna block 110 may define, either in whole or in part,one or more waveguides as part of an antenna array comprising one ormore antennae. Thus, as depicted in FIG. 1, antenna block 110 comprisesa plurality of posts 122 arranged to define a plurality of waveguidegrooves therebetween.

It should be understood that although, in preferred embodiments, aplurality of antennae may be provided and therefore a plurality ofcorresponding antennae structures—such as a plurality of waveguides,grooves, etc.—may be provided, it is contemplated that some embodimentsmay comprise an array having a single antenna and therefore only asingle waveguide, for example. Such antenna/waveguide/groove may curveabout the block/assembly rather than be in a series of parallel lines insome embodiments. As another example, in some embodiments, grooves,slots, or the like may be arranged in a disc formation, or any othersuitable formation, including linear, curved, etc.

In the depicted embodiment, each of the grooves is defined by a firstplurality of posts 122 extending in a row and a second plurality ofposts 122 extending in another row that, in some embodiments, may beparallel to the first plurality of posts 122. Thus, antenna 120A isdefined by two parallel rows of posts 122 and antenna 120B is similarlydefined by two parallel rows of posts 122, and so on. Antennae 120H and120I share a common row of posts 122. In other words, three rows ofposts 122 define two antennae with the middle row being used to definesides of two separate grooves/antennae.

It should be understood, however, that other grooves and/or antennae,either in the same embodiment or in other embodiments, may not bedefined by any posts 122 or other features that are shared in commonwith other grooves/antennae. For example, as also shown in FIG. 1,antennae 120A-120G are each defined by wholly independent sets of posts122. It should also be understood that, as described in greater detailbelow, in preferred embodiments, antennae 120A-120I may be partialantennae. In other words, these antennae may only comprise part of thestructure that will ultimately be used to define the full antennaestructures used in a functional RADAR or other vehicle sensor assemblyand yet will be referred to herein as “antennae” nonetheless.

As also shown in FIG. 1, each of the grooves defined by posts 122 mayfurther comprise a ridge 125 extending through the groove in between theopposing structures defining the groove. Thus, in the depictedembodiment, ridges 125 extend between the opposing posts 122 definingthe respective grooves. However, in other embodiments, including somediscussed below, grooves may be defined in other ways and/or by otherstructures, such as simply forming a groove within a solid structure(i.e., no posts extending up from the structure). Although notnecessary, ridges 125 may be preferred to enhance the characteristics ofthe waveguide by further facilitating guidance of electromagnetic wavesas desired and/or for satisfying size/dimensional demands.

In some embodiments, including the one depicted in FIG. 1, one or moreof the ridges 125 may comprise a notch 126, which may in someembodiments be positioned at a relatively central location betweenopposing ends of its respective ridge 125 and/or groove. Someembodiments may further comprise a slot or opening that in someembodiments may extend through the entire antenna block 110 from a firstside 112 of the antenna block 110 to an opposite side 114. Such slotsmay be formed in embodiments lacking ridges, and therefore typicallylacking notches, and will be discussed in greater detail below anddepicted in connection with other embodiments presented below.

As also discussed below, any or all of the waveguide structuresdiscussed above or elsewhere herein may be formed or otherwise disposedon both sides of antenna block 110. Thus, for example, posts 122, ridges125, and/or grooves may be formed on side 114 as well as, or as analternative to, side 112.

In preferred embodiments, block 110 may comprise a casting, such as acasting comprising a Zinc or other suitable preferably metal material.However, in other contemplated embodiments, block 110 may comprise aplastic or other material. In some such embodiments, metallic inserts,coatings, or the like may be used if desired. In typical sensorassemblies, which, as previously mentioned, may be configuredspecifically for use in connection with vehicles, other structures maybe combined with block/casting 110. For example, as shown in FIG. 2, aslotted layer 140 may be coupled to the antenna block 140 to form anantenna assembly 100.

Slotted layer 140 of antenna assembly 100 may comprise one or more rows145 of slots 142, which may correspond in number and/or location withthe antennae partially defined by antenna block 140. Thus, layer 140comprises six rows 145 of slots 142, which may comprise elongated slots,each of which, once layer 140 has been coupled to antenna block 140, isaligned with a respective antenna of the six antennae partially definedby block 140. As also shown in FIG. 2, rows 145 may comprise slots 142that are staggered with respect to one another.

In some embodiments, this staggering configuration may be appliedrelative to antenna block 140 such that each slot 142 extends along aside of a groove defined by posts 122 and such that each slot 142extends along an opposite side of the groove relative to its adjacentslot 142 to facilitate a desired guidance of RF or other electromagneticradiation though slots 142. However, those of ordinary skill in the artwill appreciate that a wide variety of alternative configurations arepossible depending upon the desired functionality and specifications ofthe waveguide/sensor assembly.

Preferably, slotted layer 140 comprises a metal or other conductivematerial. Layer 140 may be coupled with block 140 in a variety ofpossible ways. For example, an adhesive, solder, heat stakes, screws,other fasteners, and the like may be used to couple layer 140 to block110. In some embodiments, as discussed below, another layer, such as alayer of adhesive tape, may be inserted in between layers 110 and 140,which may, either entirely or in part, be used to provide this coupling.In embodiments in which solder is used, such solder may be applied tothe top of one or more (in some embodiments, all) of posts 122 and/orridges 125 (if present).

An alternative embodiment of an antenna assembly 300, such as a vehicleRADAR or other vehicle sensor antenna assembly, is shown in FIG. 3, someof the individual layers of which are depicted in FIGS. 4A-4C. Assembly300 again comprises an antenna block 310, which may comprise a castingin some embodiments. Block 310 comprises a plurality of waveguidegrooves 322 used to guide RF or other electromagnetic radiation, aspreviously mentioned. However, grooves 310 are defined by forming blindopenings, such as trenches, within block 310 rather than by providing aseries of posts to define one or more grooves therebetween, as withblock 110.

Block 310 may otherwise be similar to block 110. Thus, block 310 maycomprise an array of antennae structures 320 that may be used to atleast partially define a plurality of antennae for a vehicle RADAR orother sensor assembly. In some embodiments, one or more ridges 325 maybe positioned within each groove 322 to further define the waveguides asdesired. In addition, one or more of such ridges 325 may comprise anotch 326 and/or slot that, in some embodiments, may extend throughblock 310 from an upper/first surface 312 to a lower/second surface 314,which may allow for desired guidance of RF or other electromagneticwaves from one side of antenna block 310 to the other. As previouslymentioned, the antenna structures depicted on surface/side 312 may alsobe formed on surface/side 314 if desired.

A slotted layer 340 may be coupled to block 310. Slotted layer 340 maybe similar to slotted layer 140 and may therefore comprise a pluralityof rows 345 of slots 340. Slots 342 may be positioned and configured asdesired. However, in the depicted embodiments, slots 342 may beelongated and/or positioned in rows 345 that extend adjacent to arespective groove 322 in a staggered manner as previously described.Preferably, one or more (or each) of slots 342 is positioned adjacent toa respective groove 322 such that the slot 342 is at least partially (insome such embodiments, fully) aligned with the respective groove 322 sothat relatively little or none of the groove 322 is blocked by materialof the slotted layer 340.

Unlike antenna assembly 100, antenna assembly 300 is shown with a thirdand/or middle layer positioned in between block 310 and slotted layer340, namely layer 350. In preferred embodiments, layer 350 comprises anadhesive layer. Adhesive layer 350 may be made up of, for example, anadhesive tape, such as a conductive adhesive tape, or another suitable,preferably conductive material. In other embodiments, adhesive layer 350may be defined by one or more soldered regions.

As shown in FIG. 3, in preferred embodiments, layer 350 comprises aplurality of openings 352. Openings 352 may correspond in number withand be positioned adjacent to each of the grooves 322 of antennaestructures 320. Similarly, each of openings 352 is preferably positionedadjacent to a respective row 345 of slots 342 of layer 340 on theopposite side. Preferably, openings 352 are at least partially (in somecases fully) aligned with grooves 322 and/or slots 342.

FIG. 5 depicts a cross-sectional view of a more complete example ofassembly 300 showing the preferred alignment of each of the variouslayers and also depicting a PCB layer 370 that may be coupled to surface314 of block 310. In the depicted embodiment, a series of PCBs 370 areshown, each corresponding with a respective antenna. However, as thoseof ordinary skill in the art will appreciate, in other embodiments asingle PCB may form layer 370 and be used to connect a plurality ofantennae. As also best seen in FIG. 5, notches 326 are formed adjacentto a series of slots 327 that may extend through block 310, in someembodiments between sides 312 and 314 of block 310.

In some embodiments, one or more of the PCBs, or a single layercomprising a PCB, may be coupled to block 310 by providing a patch. Insome such embodiments, the patch may comprise an array of posts thatmay, form a partial waveguide so that the PCB and block/casting togethermay form a waveguide. Alternatively, the posts of this patch may bereplaced by continuous walls and/or grooves that may be partially orfully aligned with similar features in the block/casting and/or otherlayers in the assembly.

FIG. 6 is a partially-exploded, cross-sectional view of still anotherembodiment of a sensor antenna assembly 600. Assembly 600 comprises anumber of additional features and components, any one or more of whichmay be applied to any of the other embodiments discussed herein.Assembly 600 therefore comprises an antenna block 610 that defines aseries of structures that are used to partially define individualantennae for a RADAR or other vehicle sensor assembly.

Thus, block 610 comprises a first side 612 defining a first array ofwaveguide grooves 622 and a second side 614 defining a second array ofwaveguide grooves 622. Each of the waveguide grooves 622 of side 612 mayat least partially overlap with a respective groove 622 of side 614. Insome such embodiments, each of the waveguide grooves 622 of side 612 maybe aligned with a respective groove 622 of side 614, as shown in FIG. 6.A subset of the grooves 622 of block 610 further comprises a ridge 625positioned therein. Of course, in other embodiments, all grooves 622 maycomprise such a ridge 625 or, alternatively, no such ridges may beprovided. For example, rectangular waveguides may be used in someembodiments without ridges. Grooves 622 may be defined by forming acontinuous trench within block 610. Alternatively, grooves 622 may bediscontinuous, such as by providing a series of adjacent posts 623 orother structures that collectively define a groove, as previouslymentioned and depicted in connection with other figures.

As also previously mentioned in connection with other embodiments,various layers may be provided to one or both sides of block 610. Thus,as shown in FIG. 6, layer 650, which may comprise a conductive adhesivelayer, such as a conductive tape, may be applied to side 612, preferablysuch that a series of openings 652 within layer 650 are at leastpartially aligned, respectively, with grooves 622.

Layer 650 or, in other embodiments, a suitable adhesive, solder, and/orfasteners, may be used to apply layer 640 to antenna block 610. Layer640 may comprise, for example, a conductive plate that may comprise aplurality of slots 642. Slots 642 may be smaller than the openings 652of layer 652 if desired and may be used to direct RF signals or the liketherethrough. It is also contemplated that any of the disclosed slotsmay, in alternative embodiments, be sized differently or not provided.For example, in some embodiments, layer 650 may lack slots altogether.

In the embodiment depicted in FIG. 6, still another layer may be appliedto antenna block 610. More particularly, assembly 600 further comprisesa top layer 660, which may be used to provide a radome or liquid/weatherseal to the assembly 600. Thus, in some embodiments, layer 660 maycomprise a plastic film or other non-conductive material. In some suchembodiments, layer 660 may comprise an adhesive plastic film. However,alternatively, layer 660 may be applied by use of a separate adhesive orother coupling means. Preferably, layer 660 applies a waterproof seal toassembly 600 to protect the unit from damage, which may allow assembly600 to be mounted to the exterior of a vehicle.

In some embodiments and related manufacturing methods, a sub-assemblycomprising a plurality of layers forming a self-contained weather sealor “sticker” may be provided. For example, all three of layers 640, 650,and 660 may be formed during manufacturing in a sandwich configurationthat may be simply applied to the top of the antenna block 610 by use ofan adhesive. In some such embodiments, the adhesive may be part of thesandwich assembly so that the weather seal assembly may be applied toantenna block 610 similar to a sticker. Of course, in some embodiments,less than all of the layers depicted in FIG. 6 or, in other embodiments,additional layers, may be included in this weather seal/stickerassembly.

To further facilitate such mounting, one or more mounting features maybe provided to facilitate mounting or other coupling to a vehicle. Forexample, the depicted embodiment comprises mounting tabs 615/617.Mounting tabs 615 and 617 may, in some embodiments, comprise integralcomponents of antenna block 610. Thus, in embodiments in which antennablock 610 comprising a casting, mounting tabs 615 may be part of a moldused to manufacture this casting. This may provide simplicity byallowing for formation of mounting features on assembly 610 withoutrequiring separate coupling of such features to the assembly. However,of course, in alternative embodiments mounting tabs and/or features maybe separately attached to the assembly 610. It should also be understoodthat, whereas two opposing mounting tabs 615/617 are shown in theembodiment of FIG. 6, any alternative number of mounting tabs may beused in other embodiments as desired to facilitate a secure couplingwith a vehicle.

Both of mounting tabs 615/617 further comprise a mounting featureconfigured to engage a corresponding mounting feature on a vehicle. Inthe depicted embodiment, these mounting features comprise openings 618,which may be threaded so as to receive a bolt or other threaded fastenertherethrough. However, a wide variety of alternative mounting featuresare contemplated, including snap-fit prongs, grooves, or other snap-fitcoupling elements, mounting brackets, and mounting fasteners or othermounting posts that may be received within a corresponding opening of avehicle.

On side 614 of antenna block 610, other layers similar to those on side612 may be provided. Thus, layer 680 may be used to couple a PCB layer670 to antenna block 610. Layer 680 may be similar to layer 650 and maytherefore comprise another conductive tape or other conductive adhesivelayer, such as a solder layer. PCB layer 670 may comprise, for example,an FR-4 PCB material, which may form a top of the waveguides defined byantenna block 610 and related structures described above.

Assembly 600 further comprises a cover 690, which may be used to provideadditional structure to the assembly and/or to provide a seal to thelower portion of the assembly. In the depicted embodiment, cover 690comprises a frame 692 that may be used to provide the foundation forenclosing the elements/layers coupled to the lower surface 614 ofantenna block 610 and/or provide this seal. Thus, frame 692 of cover 690is coupled to antenna block 610 such that at least a portion of theantenna block 610 is recessed within cover 690.

In preferred embodiments, and in preferred implementations of methodsfor manufacturing, cover 690 and, more particularly, frame 692 of cover690 in even more preferred embodiments and implementations, may becrimped to antenna block 610. More particularly, antenna block 610 maycomprise one or more recesses, such as recess 616, within which thecover 690 and/or frame 692 may be crimped or otherwise coupled toantenna block 610. In some embodiments, recess 616 may comprise anannular recess such that cover 690 is crimped to antenna block 610 abouta full perimeter of block 610. Following this crimping, rim 694 isformed, which sits within recess 616 to couple cover 690 to the antennablock 610. In some embodiments, frame 692 may comprise an aluminum orother suitable material that preferably may be crimped, bent, molded,such as by forming rim 694, as mentioned.

Cover 690 may further comprise a shell 695, which may define a seal(preferably a water/weatherproof seal) for cover 690. In someembodiments and implementations, shell 695 may comprise a sealant, suchas a potting compound or other material that may be applied to theexterior surface of shell, preferably, again, in a manner so as toprovide a liquid seal, such as by overmolding shell 695 to the assembly.Thus, in some embodiments, the sealant/overmolding may be applied so asto extend into recess 616 and/or other crevices or other features of theassembly to provide a suitable seal for the intended purpose of theassembly.

As shown in FIG. 6, in some embodiments, mounting tabs 615/617 mayprotrude beyond a perimeter of cover 690 so as to allow forclearance/spacing to facilitate coupling of assembly 600 with a vehicle.

Various other standard elements may be provided as needed, such aselectrical connector 605. Although not shown or described in detail,electrical connector 605, or a cord/wire associated with electricalconnector may, in some embodiments, extend through cover 690.

FIG. 7 depicts a cross-sectional view of yet another example of anantenna assembly 700, such as a vehicle RADAR or other vehicle sensorantenna assembly, according to other embodiments. Assembly 700 comprisesan antenna block 710, which may comprise a casting, such as a metalliccasting in some embodiments or, alternatively, a thermoplastic casting,for example. Block 710 comprises a plurality of waveguide grooves 722used to guide RF or other electromagnetic radiation, as previouslymentioned. Grooves 710 are defined by forming blind openings, such astrenches, within block 710, as previously mentioned.

Block 710 comprises an array of antennae structures that may be used toat least partially define a plurality of antennae for a vehicle RADAR orother sensor assembly. In some embodiments, one or more ridges 725 maybe positioned within each groove 722 to further define the waveguides asdesired. Although not shown in FIG. 7, in some embodiments, one or moreof such ridges 725 may comprise a notch and/or slot that, in someembodiments, may extend through block 710 from an upper/first surface712 to a lower/second surface 714, which may allow for desired guidanceof RF or other electromagnetic waves from one side of antenna block 710to the other.

The embodiment of FIG. 7 further comprises a plurality of antennaestructures formed on surface/side 714 that are aligned (in alternativeembodiments, they may simply overlap to a certain extent or not bealigned at all) with the corresponding antennae structures onsurface/side 712.

An upper slotted layer 740 is coupled to block 710 adjacent to side 712.Slotted layer 740 may be similar to slotted layer 140 and may thereforecomprise a plurality of rows of slots 740 corresponding to the rows ofgrooves 722 and/or other antennae structures. A middle layer 750, whichmay comprise an adhesive layer, is positioned in between block 710 andslotted layer 740. Middle/adhesive layer 750 may be made up of, forexample, an adhesive tape, such as a conductive adhesive tape, oranother suitable, preferably conductive material. In other embodiments,adhesive layer 750 may be defined by one or more soldered regions.

As also depicted in FIG. 7, in preferred embodiments, layer 750 alsocomprises a plurality of openings 752. Openings 752 may correspond innumber with and be positioned adjacent to each of the grooves 722 ofeach of the antennae structures. Similarly, each of openings 752 ispreferably positioned adjacent to a respective row of slots 742 of layer740. Preferably, openings 752 are at least partially (in some casesfully) aligned with grooves 722 and/or slots 742.

A top layer 760 may also be applied to antenna block 710, which aspreviously mentioned, may comprise a plastic film or othernon-conductive material. In some such embodiments, layer 760 maycomprise an adhesive plastic film. Again, this layer may be used toprovide a radome or liquid/weather seal to the assembly 700.

In some embodiments and related manufacturing methods, a sub-assemblycomprising a plurality of layers forming a self-contained weather sealor “sticker” may be provided. For example, all three of layers 740, 750,and 760 may be formed during manufacturing in a sandwich configurationthat may be simply applied to the top of the antenna block 710 by use ofan adhesive. In some such embodiments, the adhesive may be part of thesandwich assembly so that the weather seal assembly may be applied toantenna block 710 similar to a sticker. Of course, in some embodiments,less than all of the layers depicted in FIG. 7 or, in other embodiments,additional layers, may be included in this weather seal/stickerassembly.

Assembly 700 further comprises another layer 780, which may be similaror identical to layer 740, adjacent to side 714. Layer 780 may alsocomprise a plurality of slots or openings (not visible in FIG. 7) that,again, may correspond in number and/or location with the variousantennae structures positioned on this side of block/casting 710.

To facilitate mounting of assembly 700 to a vehicle, one or moremounting features may be provided to facilitate mounting or othercoupling to a vehicle. For example, the depicted embodiment comprisesmounting tabs 715/717. These mounting may, in some embodiments, compriseintegral components of antenna block 710. Mounting tabs 615/617 mayfurther comprise one or more mounting features configured to engage acorresponding mounting feature on a vehicle. In the depicted embodiment,these mounting features comprise posts or studs 718, which may bethreaded in some embodiments. However, again, a wide variety ofalternative mounting features are contemplated, including threadedholes, snap-fit prongs, grooves, or other snap-fit coupling elements,mounting brackets, and other mounting or other coupling elements.

Assembly 700 further comprises a PCB layer 770 that may be coupled tosurface 714 of block 710. PCB layer 770 may comprise, for example, anFR-4 PCB material, which may form a top of the waveguides defined byantenna block 710 and related structures described above. The variouscomponents/layers on this side may be enclosed within a casing or cover790, which may be used to provide additional structure to the assemblyand/or to provide a seal to the lower portion of the assembly. In thedepicted embodiment, cover 790 comprises a frame 792 that may be used toprovide the foundation for enclosing the elements/layers coupled to thelower surface 714 of antenna block 710 and/or provide this seal. Thus,frame 792 of cover 790 is coupled to antenna block 710 such that atleast a portion of the antenna block 710 is recessed within cover 790.

In preferred embodiments, and in preferred implementations of methodsfor manufacturing, cover 790 and, more particularly, frame 792 of cover790 in even more preferred embodiments and implementations, may becrimped to antenna block 710. More particularly, antenna block 710 maycomprise one or more recesses, such as recess 716, within which thecover 790 and/or frame 792 may be crimped or otherwise coupled toantenna block 710.

Following the aforementioned crimping, rim 794 may be formed, which sitswithin recess 716 to provide a rigid coupling between cover 790 andblock 710. In some embodiments, frame 792 may comprise an aluminum orother suitable material that preferably may be crimped, bent, molded,such as by forming rim 794, as mentioned.

Cover 790 may further comprise a shell 795, which may define a seal(preferably a water/weatherproof seal) for cover 790. In someembodiments and implementations, shell 795 may comprise a pottingcompound or other sealant material that may be applied to the exteriorsurface of shell, preferably, again, in a manner so as to provide aliquid seal, such as by overmolding shell 795 to the assembly. Thus, insome embodiments, the sealant/overmolding may be applied so as to extendinto recess 716 and/or other crevices or other features of the assemblyto provide a suitable seal for the intended purpose of the assembly.

Although not shown in the figure, various other standard elements may beprovided as needed, such as an electrical connector, cords, wires,receivers, transmitters, or other desired components.

The foregoing specification has been described with reference to variousembodiments and implementations. However, one of ordinary skill in theart will appreciate that various modifications and changes can be madewithout departing from the scope of the present disclosure. For example,various operational steps, as well as components for carrying outoperational steps, may be implemented in various ways depending upon theparticular application or in consideration of any number of costfunctions associated with the operation of the system. Accordingly, anyone or more of the steps may be deleted, modified, or combined withother steps. Further, this disclosure is to be regarded in anillustrative rather than a restrictive sense, and all such modificationsare intended to be included within the scope thereof. Likewise,benefits, other advantages, and solutions to problems have beendescribed above with regard to various embodiments. However, benefits,advantages, solutions to problems, and any element(s) that may cause anybenefit, advantage, or solution to occur or become more pronounced, arenot to be construed as a critical, a required, or an essential featureor element.

Those having skill in the art will appreciate that many changes may bemade to the details of the above-described embodiments without departingfrom the underlying principles of the invention. The scope of thepresent inventions should, therefore, be determined only by thefollowing claims.

1. A method for manufacturing a vehicle sensor module, the methodcomprising the steps of: forming a sub-assembly comprising a pluralityof stacked layers formed into a self-contained radome; adhering thesub-assembly to a first side of an antenna block, the first sidecomprising a plurality of waveguide grooves formed therein, such thatthe sub-assembly provides a weatherproof seal to each of the pluralityof waveguide grooves formed in the antenna block; coupling a PCB layerto a second side of the antenna block opposite the first side; andseating the antenna block within a cover such that the second side isprotected by the cover and the first side is protected by theself-contained radome.
 2. The method of claim 1, wherein the covercomprises a closed bottom and an open top.
 3. The method of claim 2,wherein the step of seating the antenna block within the cover comprisescoupling the cover to the antenna block such that the second side of theantenna block is recessed within the cover adjacent to the closedbottom.
 4. The method of claim 1, wherein the step of seating theantenna block within the cover comprises crimping the cover to theantenna block.
 5. The method of claim 4, wherein the antenna blockfurther comprises a recess, and wherein the step of crimping the coverto the antenna block comprises crimping the cover to the antenna blockwithin the recess.
 6. The method of claim 1, wherein the self-containedradome comprises three layers.
 7. The method of claim 6, wherein one ofthe three layers comprises an adhesive film.
 8. The method of claim 7,wherein one of the three layers comprises a conductive layer.
 9. Themethod of claim 8, wherein the conductive layer comprises a plurality ofopenings, and wherein each of the plurality of openings is aligned witha corresponding waveguide groove of the plurality of waveguide grooves.10. The method of claim 8, wherein one of the three layers comprises aslotted layer comprising a plurality of slots configured to receiveelectromagnetic signals therethrough, and wherein each of the pluralityof slots is aligned with a corresponding waveguide groove of theplurality of waveguide grooves.
 11. The method of claim 6, wherein eachof the three layers is flexible such that the entire self-containedradome is flexible.
 12. The method of claim 1, wherein the antenna blockfurther comprises at least one mounting tab configured for mounting thevehicle sensor module to a vehicle.
 13. The method of claim 12, whereinthe step of crimping the cover to the antenna block within the recess isperformed such that the at least one mounting tab protrudes beyond aperimeter of the cover.
 14. The method of claim 12, wherein the at leastone mounting tab protrudes beyond a perimeter of both the antenna blockand the self-contained radome.
 15. The method of claim 1, wherein theantenna block comprises a second plurality of waveguide grooves formedon the second side.
 16. The method of claim 15, further comprisingapplying an adhesive layer to the second side of the antenna block. 17.The method of claim 16, wherein the adhesive layer applied to the secondside comprises a plurality of openings, and wherein each opening of theplurality of openings of the adhesive layer on the second side isaligned with a corresponding waveguide groove of the plurality ofwaveguide grooves formed on the second side.